Controlled flow polymer blends and products including the same

ABSTRACT

The present invention is directed to polymer blends having controlled flow properties. The polymer blends can be useful in various applications including bonding systems and additive delivery systems, which can provide durable binding and/or delivery and/or affixing of additives. The polymer blends can include at least two different components, at least one being a polymer component having a higher molecular than the other of the components. When heated to an activating temperature, the resultant blend exhibits desirable flow or wet out properties without applied pressure. Despite the controlled flow properties, the blends do not exhibit blocking or fusing properties typically associated with high flow polymer materials.

FIELD OF THE INVENTION

The present invention relates to polymer blends and articles includingthe same. More particularly, the present invention relates to polymerblends having useful flow or wetting properties without undesirableblocking properties and to products including the same.

BACKGROUND OF THE INVENTION

Fibrous materials having various functionalities are useful in manydifferent applications. Often, it can be useful to treat a fibrousmaterial to impart or enhance a particular property thereof, such asflame retardance, UV resistance, and the like.

The functionality of a fibrous material can be modified by introducing asuitable additive into the fibrous structure. Many natural fibersexhibit polar functionality (such as hydroxyl functionality found incotton fibers), due at least in part to the biological origins of suchmaterials. Nonetheless, functional groups present in many naturalfibrous materials can exhibit limited reactivity, and accordingly,additive formulations can simply sit in a bead and not wet out thesubstrate.

Natural (plant and animal) fibers can be blended with synthetic fibersto formulate functionalized fibrous materials. The differences inphysical properties between synthetic and natural fibers, however, canresult in phenomena like pilling, which can reduce the desirability andeffectiveness of the blend. Other treatments for imparting functionalityto natural fibrous materials may be limited to use with liquid vehicles.Yet, to penetrate a fibrous material sufficiently to provide adequatebonding, the fibrous materials are typically saturated with the liquid,which results in a large volume of solution to be handled, removed fromthe fabric, and disposed in compliance with environmental regulations.

It can be difficult to introduce functional additives into syntheticfibrous materials as well. For example, the crystallinity of certainsubstrates, such as polypropylene fibrous articles, can present arelatively hard, non-reactive surface to a would-be binder. Manypolyester copolymers such as are used as binders in nonwoven fabricsalso do not adhere well to polypropylene and/or do not meet neededtemperature-flow profiles. Further, the effectiveness of an additive maydepend on surface area presentation. For example, silver antimicrobialagents operate via release of silver ions. Yet such activity can beimpeded if the antimicrobial agent is buried deep within a treatedsynthetic fiber or fabric. It can be difficult, however, to locate anactive agent on or near the surface of a synthetic fiber, and thisdifficulty can be acerbated in applications dictating relatively minoramounts of the active agent.

In addition to the issue of effectively introducing an additive into afibrous material, it can also be difficult to impart permanency to thetreated product. Topical treatments can exhibit limited durability orcan be readily reversed, particularly when the fibrous material isexposed to washing, cleaning solvents, and other environmental forcesthat the material itself may be able to withstand, but a coating maynot. Even for solvent based additive systems, which can generallywithstand numerous washings, there is a desire to move away from solventbased systems due to environmental concerns.

In addition, the additive carrier or binder should have adequate thermalflow to allow it to be applied under commercially feasible conditionsand time frames, for example, at lower bonding temperatures and/orresidence times. Many polymer systems with high molecular weights (whichcan be desirable for the requisite physical properties) may lackflowability sufficient to penetrate through a fibrous material.Accordingly, the use of high molecular weight polymer systems mayrequire the application of pressure, such as by calendering. Further,high molecular weight polymer systems may require relatively highbonding temperatures and/or residence times, which can increase energycosts and bonding times associated with using the same.

Polymers have been developed for use in applications requiring relativegood flow, such as hot melt adhesion and coating applications. Suchpolymers can have relatively high melt flow rates so as to impartdesirable flow properties to the resultant product. Such polymers,however, typically have lower molecular weights, and thus can exhibitexcessive molecular mobility and can be generally tacky or block atnormal warehousing and handling conditions. Stated differently, productsformed of polymers having relatively high melt flow rates can become“sticky” or “tacky” and thus tend to block, that is, to stick together,when subjected to conditions of elevated temperatures and increasedhumidity, such as associated with the commercial transportation andwarehousing of products. Such polymers can also stick to and bind up onprocessing equipment, thereby decreasing manufacturing efficiencies.

Various techniques have been proposed to reduce the tendency of highflow polymers to block. Anti-tack agents are offered commercially toimprove the block resistance of various polymers. Although useful, manyanti-tack agents are only marginally effective, and further may beeffective only with specific types of polymers.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to polymer blends exhibiting desirableflow properties without also exhibiting the blocking propertiestypically associated with high flow polymers. The polymer blends of theinvention are capable of substantially wetting out a surface at a flowactivating temperature without requiring the application of substantialpressure. Yet despite the melt flow properties of the blends, thepolymer blend after applying and solidifying further exhibits blockingresistance properties, thereby facilitating manufacturing and downstreamstorage and transportation of products produced using the polymerblends.

The polymer blends of the invention include at least two, or more,components that differ from one another with regard to molecular weight.The polymer blend includes a first blend component including at leastone polymer having a first molecular weight and a second blend componentincluding at least one compound having a second molecular weight that isless than the first molecular weight of the at least one polymer of thefirst blend component. The molecular weight of the at least one polymerof the first blend component is sufficiently high to prevent thesubstantial wet out of the at least one polymer of the first blendcomponent without the application of pressure at the activatingtemperature of the blend. The second molecular weight of the at leastone compound of the second component of the blend is sufficiently low sothat the at least one compound of the second component of the blendexhibits a level of molecular mobility sufficient to limit itsusefulness by itself for the production of an article such as a fiber orfabric. The at least one compound of the second component of the blendmay, for example, exhibit such a high level of molecular mobility thatwhen processed alone, its usefulness is limited because it may besusceptible to blocking, and/or because it may exhibit too much creep,and/or it may have inadequate melt strength or viscosity to beprocessed. Yet together the blend components can provide a combinationof properties including sufficient flow for fiber formation and/orwet-out of a desired substrate without causing problems associated withblocking or creep.

The polymer blends of the invention can be useful in the production ofproducts, such as binder fibers, that can be tailored to exhibit a rangeof various properties, such flow rates, activation temperatures, meltstrengths, blocking temperatures, and the like, depending on the desiredapplication of the product. The inventor has surprisingly found thatpolymer blends can be prepared of at least two components having highand low molecular weights, relative to one another, that can exhibit amelt strength that is higher than expected given the resulting viscosityof the blend. This is particularly surprising and useful in that itallows the production of articles, such as fibers, from materials thatcan have unusually low viscosity when remelted, as for instance whenused as a binder fiber. The invention accordingly can provide amechanism to fine tune polymer formulations for specific applications.

In exemplary embodiments of the invention, at least one of thecomponents can include a substantially crystalline polymer, which canpromote a sharp flow profile. In other exemplary embodiments of theinvention, at least one of the components can include a functionalizedpolymer component, such as a maleic anhydride functionalized polyolefin,which can improve wetting and/or adhesive properties of the blend. Inyet other embodiments of the invention, the polymer blend can include atleast one additive.

One exemplary polymer blend of the invention capable of substantiallywetting out a surface at a flow activating temperature without requiringthe application of substantial pressure, the polymer blend furtherhaving blocking resistance properties, can include at least about 10percent by weight, based on the total weight of the polymer blend, of afirst blend component including at least one polymer having a firstmolecular weight and a glass transition temperature T_(g), and at leastabout 10 percent by weight, based on the total weight of the polymerblend, of a second blend component including at least one substantiallycrystalline compound having a second molecular weight that is less thanthe first molecular weight of the at least one polymer of the firstblend component and having a melting point that is greater than theT_(g) of the at least one polymer of the first blend component. In thisembodiment of the invention, at least one of the first and secondcomponents can include a functionalized polymer, such as afunctionalized polyolefin, including maleic anhydride modifiedpolyolefins.

In other aspects, the present invention also provides a polymericbonding system and bonding methods using the same. The polymeric bondingsystem of the invention can be in the form of an article, such as afibrous material, film, foam, coating, a particulate material, and thelike, formed of the polymer blend and combinations thereof.

Other aspects of the invention are directed to a polymeric deliverysystem and additive delivery methods using the same. The polymericdelivery system of the invention can include the polymer blend describedherein in combination with an additive, and can also be provided in theform of an article, such as a fibrous material, film, foam, coating, aparticulate material, and the like. The polymer delivery system can beapplied to a substrate and treated (heated) to promote flow and form acoating. In this embodiment of the invention, the coating can berelatively low add on, can be substantially discontinuous (for examplesmall islands) or substantially continuous, and/or can be applied in apattern by various techniques. The coating may also be thin and/orflexible, which can aid durability.

The polymer bonding system and the polymeric delivery system of theinvention and associated methods can be useful in the production ofvarious articles, including fibrous webs, yarns, and the like and cansecure additives to various substrates including natural fibers havinglimited polar functionality.

Another aspect is directed to composite articles that include a matrixmaterial and the polymer blend of the invention. The matrix material canbe selected from fibrous materials, such as synthetic and naturalfibers, and cellulosic materials, such as wood fibers and particles. Thecomposite articles can further include an additive. An exemplaryembodiment of this aspect of the invention includes an article formed ofcotton fibers having an additive, such as an antimicrobial additive,dispersed throughout via fibers formed of a mixture of the polymer blendof the invention and the antimicrobial additive.

Yet another aspect of the invention is directed to an activatable yarn.The activatable yarn includes a plurality of fibrous materials formed ofa synthetic polymer having a first molecular weight and a functionalizedadditive for promoting adhesion of the synthetic polymer to anothermaterial and having a second molecular weight that is less than thefirst molecular weight of the synthetic polymer. Exemplary embodimentsof this aspect of the invention include polyolefin and polyester yarnsincluding a maleic anhydride modified polyolefin functionalized additiveor an amine functionalized additive.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and in which:

FIG. 1 is a photomicrograph of particles of an exemplary polymer blendmaterial in accordance with the present invention;

FIGS. 2A and 2B are photomicrographs illustrating penetration of apolymer blend in accordance with the present invention into a fibroussubstrate;

FIGS. 3A and 3B are photomicrographs illustrating a fibrous substratefollowing application of an exemplary polymer blend in accordance withthe present invention; and

FIGS. 4A, 4B and 4C are photomicrographs illustrating droplet wicking ofa polymer blend of the present invention along a fiber surface.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter inthe following detailed description of the invention, in which some, butnot all embodiments of the invention are described. Indeed, thisinvention may be embodied in many different forms and should not beconstrued as limited to the embodiments set forth herein; rather, theseembodiments are provided so that this disclosure will satisfy applicablelegal requirements. As used in the specification, and in the appendedclaims, the singular forms “a”, “an”, and “the” include plural referentsunless the context clearly dictates otherwise.

The polymer blends of the present invention can have desirable yetcontradictory properties. The polymer blends can exhibit wet outproperties that can be useful in various applications, yet surprisinglythe inventor has also found that the polymer blends of the invention canalso exhibit desirable blocking resistance (or anti-blocking) anddurability properties as well. The ability to formulate the polymerblends of the invention to provide contradictory properties withoutsignificantly diminishing the same is surprising in view of thetradeoffs typical in polymer blending. That is, as will be recognized bythe skilled artisan, the properties of a polymer blend typically are notsimply a linear mixture of those of the constituent polymers, but ratherthe blend properties that result are often inferior to that of a linearprediction. For example, modifying the melt viscosity of a polymer usedin the production of hot melt adhesives by blending with another polymerto reduce tackiness can negatively impact the desired flow of theresultant product and render is useless for its intended application.Conversely, blending a high melt strength polymer with another polymerto improve flow properties can similarly result in a product that nolonger useful for its intended purpose.

The polymer blends of the invention can substantially wet out a surfaceat a given activating temperature without requiring the application ofsubstantial pressure. Stated differently, the polymer blends of theinvention are readily flowable under activating temperature conditionswithout requiring the concurrent application of pressure to promote orfacilitate polymer flow. Yet, despite the ready flow or wettingproperties of the polymer blends of the invention, in contrast toconventional flowable polymers, the polymer blends of the invention donot exhibit substantial blocking problems.

Reference herein to substantially “wetting out” a surface to which thepolymer blend is applied will be readily understood by the skilledartisan and can be assessed using known techniques. In exemplaryembodiments of the invention, the polymer blend can substantially wetout a surface to which is has been applied without requiring theapplication of substantial pressure in about one hour or less, and canbe applied in as low as a few minutes (for example, less than or abouttwo minutes) at a selected activating temperature, although the periodfor wetting a substrate surface can fall outside of this range as well.As will be appreciated by the skilled artisan, the term “wet-out” of asubstrate surface generally refers to contact angles of less than about90 degrees, or less than about 135 degrees, etc., which can beevaluated, for example, using microscopy techniques. Sometimes colorantsare used in coating or binders to enhance the contrast. The contactangle of an exemplary polymer blend of the invention is illustrated, forexample, in the droplet of FIG. 3.

The flow activating temperature can vary depending on various factorsbut typically is a temperature ranging from about 100° C. to about 150°C., including flow activating temperatures of about 125° C., althoughpolymer blends exhibiting substantial wetting properties at activatingtemperatures outside of this range can also be useful in accordance withthe present invention. As will be appreciated by the skilled artisan,the term “activating temperature” as used herein refers to thetemperature at which the polymer blend will flow (for example, thetemperature at which the polymer blend in the form of a coating, fabricor other article as discussed herein will flow) and does not refer tothe temperature of an oven, dye bath, etc. through which the article maybe passing.

In one exemplary embodiment of the invention, the polymer blend canexhibit a flow activating temperature of about 100° C. Such systems canbe designed to exhibit very high flow when the substrate to which theblend is applied, for example, passes through a low temperature dryingoven (i.e. enough heat to drive off water), such as used with cotton orother natural fibers, or is exposed to high temperature water or steam.The low activating temperature can minimize discoloration (yellowing)that can occur with cotton. The blends can flow substantially in hightemperature water conditions, such as that exhibited by manyconventional dye baths and/or at temperatures used in fabric dryingprocesses. The onset of softening can be well above 55° C. (131° F.) sothat the flow transition can be sharp to avoid tackiness or blocking,for example, under hot summer conditions normally encountered inwarehousing and transportation. Thus, despite the 100° C. activatingtemperature, advantageously in this embodiment of the invention, theresultant polymer blend is not tacky and does not block above about 55°C. This system can have the highest flow relative to the two exemplarysystems described as follows and can be suitable for powdered delivery(for example via foam, spray, slurry, and the like) to a substrate suchas a cotton fabric in applications for which flow under fabric dryingconditions and/or high temperature water conditions is advantageous orrequired.

In another exemplary embodiment of the invention, the polymer blend canexhibit a flow activating temperature of about 125° C. Such systems canbe substantially inert at boiling water temperatures yet can flow wellin an autoclave, for example. Such systems can be suited for powdereddelivery to a substrate, such as a cotton fabric, in applications forwhich stability in hot water, such as in washing, is advantageous orrequired.

In yet another exemplary embodiment of the invention, the polymer blendcan have an activating temperature of about 150° C. Such systems canhave higher melt strengths and accordingly can be more readily melt spunto form a fibrous article, such as a component of a multicomponent fiberor filament (for example, a sheath component of a bicomponent sheathcore fiber). The resultant higher viscosity exhibited by the polymerblends in accordance with this embodiment of the invention can result inlonger penetration times at temperatures of less than 150° C. (forexample about 125° C.), but viscosity can decrease at increasingtemperatures, including temperatures approaching 150° C., and/or usingfiner dispersions of the solid binder and/or more penetrating radiantenergy for faster heat-up. Such systems can be suited for delivery viabicomponent fibers introduced into a substrate, for example, by blendingthe bicomponent fibers with other fibers (natural fibers such as cottonfibers and/or other synthetic fibers).

The polymer blends can be applied to any suitable substrate, asdiscussed in more detail below. Suitable substrates can havesubstantially smooth surfaces or can include a plurality of voids orinterstices (such as can be present along the surface of a fibroussubstrate) into which the polymer blend can flow and substantially fill.

As used herein, the term “blocking” refers to the “stickiness” or“tackiness” polymer products can exhibit when exposed, either in the rawmaterial state or after activation and resolidification, to elevatedtemperatures and/or other environmental conditions (such as humidity)during processing, storage, and/or transportation. Blocking can beparticularly problematic in the storage and/or transportation ofproducts formed of readily flowable polymers that are subjected toextremes in ambient temperature, humidity and other conditions that canresult in undesired adhesion of the products to one another, or to otherobjects.

In contrast to many conventional flowable polymers, the polymer blendsof the invention exhibit block resistant (or anti-blocking) properties,without requiring the addition of substantial amounts of anti-blockingagents. The polymer blends of the invention accordingly are notsusceptible to developing a tacky or sticky feel when cooled fromelevated temperatures such as those used in polymer processing or whenpackages or rolls are exposed to expected extremes of temperature,humidity and other environmental conditions to which a polymer productcan be exposed during transportation and storage.

As will be appreciated by the skilled artisan, blocking can be evaluatedusing procedures known in the art. For example, pellets or powder can belayered several deep in an aluminum pan, which is then placed in aconvection oven at a specified time for a specified temperature. Theskilled artisan will appreciate what various test conditions, forexample time, temperature, humidity, and the like, to employ inanalyzing blocking properties, based on anticipated field use conditionsthat will be experienced. The pellets are then removed from the oven andcooled. If the pellets adhere to one another at all, they are judged tofail by “blocking.” Weight may be applied and blocking may appear onlyat the bottom of a container. Long storage times and potential humidityeffects may also increase actual blocking behavior.

The uniform polymer blends of the invention can include at least two, ormore, different components, wherein at least two of the componentsinclude one or more polymers or other compounds that differ from oneanother with respect to the molecular weights of the same. The polymerblends can include at least a first blend component that includes atleast one, or more, polymers having a first molecular weight and atleast a second blend component that includes at least one, or more,compounds (which may or may not be polymeric in nature) having a secondmolecular weight that is less than the first molecular weight of the atleast one polymer of the first blend component. The respective blendcomponents can also be referred to as the higher molecular weightpolymer component and the lower molecular weight component. In exemplaryembodiments of the invention, the higher molecular weight blendcomponent can include at lease one or more polymers having a molecularweight that is at least about three times, and up to about five times,or more, higher than the molecular weight of at least one or morecompounds of the lower molecular weight blend component.

Although not wishing to be bound by any theory or explanation of theinvention, it is currently believed that the blends take advantage ofthe fact that melt strength and melt viscosity follow differentfunctions of polymer molecular weight distribution. The inventors havefound combinations of high and low molecular materials that can exhibithigh melt strength or elasticity as compared to the viscosity orresistance to flow also exhibited by the blend. The resultant blends canflow well yet can also be strong and can be spun into fibers.

The molecular weight of the one or more of the polymers of the highermolecular weight blend component can be selected to prevent the one ormore polymers and/or the first blend component from substantiallywetting out a surface without the application of substantial pressureunder the same temperature conditions (flow activating temperature)under which the polymer blend will substantially wet out a surface, asdiscussed above. The higher molecular weight polymer(s) can have amolecular weight ranging from greater than about 6000 to about 50,000,and higher, number average molecular weight, for example, from about18,000 to about 30,000 number average molecular weight, althoughpolymers having a molecular weight outside of these ranges can also beuseful in the present invention so long as the higher molecular weightpolymer exhibits the wet out properties as discussed herein. The highermolecular weight polymer component can be useful in imparting desiredmelt strength to the polymer blends of the invention.

In various embodiments of the invention, the polymer(s) of the highermolecular weight blend component is selected to have a molecular weightthat is sufficiently high to impart sufficient melt strength to theblend to permit processing the polymer blend, for example, to permitmelt spinning, and quenching, the polymer blend to form a desiredproduct such as a fiber or fibrous structure, including a component of amulticomponent fiber. As will be appreciated by the skilled artisan,melt strength is commonly measured by die-swell when a polymer is exudedfrom a capillary. The practical manifestation is that molten streams ina spin cabinet can be pulled without breaking, elongating to formindividual fibers.

The molecular weight of the one or more compounds of the lower molecularweight component can be selected to be sufficiently low so that the oneor more compounds and/or the second blend component exhibits a level ofmolecular mobility sufficiently high so as to limit its usefulness forthe production of an article such as a fiber or fabric when processedalone and without combination with another component. The one or morecompounds and/or the second blend component may, for example, exhibittoo much molecular mobility so that its usefulness alone is limitedbecause it may be susceptible to blocking, and/or because it may exhibittoo much creep, and/or it may have inadequate melt strength to beprocessed. In various exemplary embodiments of the invention, the one ormore compounds of the lower molecular weight blend component can have anumber average molecular weight of about 6000 or less, for examplegreater than 0 to about 6000 number average molecular weight, forexample greater than about 500 to about 6000 number average molecularweight. Generally, the one or more compounds of the lower molecularweight blend component cannot be spun onto a package without blocking,using normal commercial fiber spinning operations.

As will also be appreciated by the skilled artisan, creep or cold flowof a polymer blend can be evaluated using an accelerated test asfollows. Pellets are loaded into a capillary rheometer such is used formelt flow testing, and a specified weight is applied (e.g. the standard2.16 kg). The temperature is then ramped up in gradual steps until theweighted piston begins to compress the pellets. The temperature at whichthis happens is noted. Cold flow can also be checked at ambienttemperatures periodically, for example, for 30 days, 60 days, etc.

In addition to the relative molecular weights of the components of theblends of the invention, the blend components, and one or more of theconstituent polymers and/or compounds thereof, can also differ withregard to melt flow rate (MFR), also as determined using conventionaltest standards, such as ASTM method D 1238B. In exemplary embodiments ofthe invention, the higher molecular weight polymer component, and/or oneor more of its constituent polymer(s), can have a melt flow rate that isless than the melt flow rate of the lower molecular weight component,and/or one or more of its constituent compound(s). Stated differently,the lower molecular weight component (and/or one or more of itsconstituent polymers) of the polymer blend can have a relatively highMFR as compared to the MFR of the higher molecular weight polymercomponent (and/or one or more of its constituent compounds).

As non-limiting examples, in exemplary embodiments of the invention, thelower molecular weight component (and/or one or more of its constituentcompounds) can have a melt flow rate that is at least about five times,and at least about ten times, or more, higher than the melt flow rate ofthe higher molecular weight polymer component (and/or one or more of itsconstituent polymers). In other embodiments of the invention, the highermolecular weight polymer component (and/or one or more of itsconstituent polymers) can have a melt flow rate of about 1 decigrams perminute at a temperature of about 125° C. as determined in accordancewith ASTM method D 1238B, or less, and the lower molecular weightcomponent (and/or one or more of its constituent compounds) can have amelt flow rate of about 100 decigrams per minute at a temperature ofabout 125° C. as determined in accordance with ASTM method D 1238B, ormore, although the invention is not so limited and polymers having meltflow rates outside of these ranges can be useful in accordance with thepresent invention.

The components, and/or one or more of the constituent polymers and/orcompounds thereof, of the blends of the invention can also differ fromone another with regard to melting point, as determined usingconventional test standards, such as differential scanning calorimetry(DSC). In exemplary embodiments of the invention, the higher molecularweight polymer component (and/or one or more of its constituentpolymers) can have a melting point that is higher than the melting pointof the lower molecular weight component (and/or one or more of itsconstituent compounds). Stated differently, the lower molecular weightcomponent (and/or one or more of its constituent compounds) of thepolymer blend can have a relatively low melting point as compared to themelting point of the higher molecular weight polymer component (and/orone or more of its constituent polymers). In exemplary embodiments ofthe invention, the higher molecular weight polymer component (and/or oneor more of its constituent polymers) can have a melting point of atleast about 10° C., for example, at least about 20° C., and for exampleat least about 50° C., or more, higher than the melting point of thelower molecular weight component (and/or one or more of its constituentcompounds).

The melting point of the uniform polymer blend itself can also vary,depending on various factors. In exemplary embodiments of the invention,the melting point of the polymer blend can be within about 20° C. of thetargeted blend application temperature (i.e., the activatingtemperature). The inventor has surprisingly found that the polymerblends exhibit the desired flow properties described herein despite thepresence of the higher molecular weight component, which typically doesnot flow until exposed to an “activating” temperature of at least about50° C. or more above its melting point. Suitable polymer componentsuseful for providing a polymer blend with a melt temperature asdescribed herein can include substantially crystalline polymers, asdiscussed in more detail below.

The molecular weight ranges of the blend components can vary dependingon a particular application or use of the blend and can be readilydetermined by the skilled artisan. Various embodiments of the inventioncan include blends of similar portions of two materials with fairlyextreme differences in flow (due to crystallinity and/or molecularweight) yet are compatible and provide synergistic properties in theblend. Such synergies can be exhibited by sufficient meltstrength/viscosity for fiber formation and/or by a flow/tack sharpprofile effect as discussed herein.

The polymer components of the polymer blends of the invention caninclude any of the types of polymers suitable for the formation of aparticular article, i.e., can be any of the types of polymer resinsknown in the art capable of being formed into article such as fibrousmaterials (including without limitation fibers, filaments, yarns,nonwoven articles, and the like, as discussed herein), films (permeableand impermeable), foams, sheets, coatings, particulate materials, andthe like, as well as combinations thereof. Examples of polymers usefulin the practice of the present invention include without limitationpolyolefins, including polypropylene, polyethylene, polybutene, andpolymethyl pentene; polyamides, including nylon 6 and nylon 6,6;polyesters, including polyethylene terephthalate (PET), polyethylenenaphthalate (PEN), polytrimethylene terephthalate (PTT),poly(1,4-cyclohexylene dimethylene terephthalate) (PCT), glycol-modifiedpolyethylene terephthalate (PETG), and aliphatic polyesters such aspolylactic acid (PLA); acrylics; thermoplastic elastomers;polyacrylonitrile; acetals; fluoropolymers; epoxies; phenoxies; vinylalcohol polymers; polyesterimides; polyhydroxyl alkanoates (PHA);polysulfone; polyetheretherketone; cellulose acetate and rayons;polyurethanes; hot melt adhesives; and the like, as well as co- andter-polymers and ionomers of these and other suitable polymers, andcombinations thereof. Polyolefins can be particularly advantageous invarious embodiments of the invention, although the invention is notlimited to use of polyolefins. Bio-based polymers which can bebiodegradable made from PLA and PHA can also be useful in variousembodiments.

Hot melt adhesives can also be useful in various embodiments of theinvention. Hot melt adhesives are typically thermoplastic polymers thatare solid at room temperature and liquid at elevated temperatures, forexample, solid at temperatures below 180° F. and low viscosity fluidsabove 180° F. Hot melt adhesives set to a bond on cooling. Hot meltadhesives can include without limitation paraffins, waxes, polyolefins,polyvinyl acetate polyamides, ethylene vinyl acetate (EVA) copolymers,styrene-isoprene-styrene (SIS) copolymers; styrene-butadiene-styrene(SBS) copolymers; ethylene ethyl acrylate copolymers (EEA); polyurethanereactive (PUR), and the like, and combinations thereof.

Thermoplastic elastomers as known in the art can also be useful invarious embodiments of the invention. Exemplary elastomers includewithout limitation polyurethane elastomeric materials; polyamideelastomeric materials; polyester elastomers; polyetherester elastomeric;polyetheramide elastomeric materials; polyolefin elastomers; elastomericstyrene block copolmyers, including diblock and triblock copolymersbased on polystyrene (S) and unsaturated or fully hydrogenated rubberblocks, which can consist of butadiene (B), isoprene (I), or thehydrogenated version, ethylene-butylene (EB); and the like andcombinations thereof.

Functionalized polymers can also be useful as one or more of thecomponents of the blends of the invention. The functionality can beselected to provide a desired thermodynamic attractive force between thepolymer blend and the target substrate to which the blend is applied,such as a natural fiber. This in turn can improve wet out of the polymerblend.

The polymers can be functionalized as known in the art to impart adesired property thereto, such as a functional group to improve wet outand/or adhesion properties of the polymer component and/or the resultantpolymer blend. Exemplary functionally modified polymers useful invarious embodiments of the invention can include, for example, variousfunctionalized polyolefins, such as but not limited to olefins modifiedby reaction with at least one at least one unsaturated anhydride,unsaturated acid or unsaturated ester. As non-limiting example,functionalized polyolefins useful in the invention can include an olefinmodified by reaction with at least one unsaturated anhydride,unsaturated acid or unsaturated ester selected from the group consistingof maleic anhydride, citraconic anhydride, itaconic anhydride,glutaconic anhydride, 2,3-dimethylmaleic anhydride, maleic acid, fumaricacid, citraconic acid, itaconic acid, mesaconic acid, glutaconic acid,acrylic acid, methacrylic acid, crotonic acid, 2-pentenoic acid,2-methyl-2-pentenoic acid, dimethyl malcate, diethyl maleatc,di-n-propyl malcate, diisopropyl maleate, dimethyl fumarate, diethylfumarate, di-n-propyl fumarate, di-isopropyl maleate, dimethylitaconate, methyl acrylate, ethyl acrylate, methyl methacrylate, ethylmethacrylate, methyl crotonate, and ethyl crotonate. Polymer blendsincluding one or more maleic anhydride modified olefins, includingwithout limitation maleic anhydride modified polypropylene and maleicanhydride polyethylene, can be particularly useful in variousapplications. As will be appreciate by the skilled artisan, some ofthese functionalities can also be created by oxidizing an olefin, andother exemplary polymers include polymers functionalized by oxidizingthe polymer, for example, by oxidizing a polyolefin.

Non-limiting examples of functionalized polymers useful in the presentinvention include maleated polyethylene commercially available from DowChemical and maleated waxes such as the Epolene waxes commerciallyavailable from Eastman Chemical Company. Also useful are polymeric ornon-polymeric compounds having one or more carboxyl, hydroxyl, and/oramine functional groups. In this embodiment, the lower molecular weightcomponent can include one or more substantially crystalline orsemicrystalline functionalized compounds, which can also be lowermolecular weight compounds that have a melting point that is higher thanthe T_(g) of at least one polymer of the higher molecular weightcomponent of the blend. Although not wishing to be bound by any theoryor explanation of the invention, it is currently believed that theincreased functionality imparted to the blends by incorporating suchfunctionalized polymers can increase wet-out and improve adhesion tocellulosics, cotton, and other natural fibers, as well as syntheticfibers spun from acrylic, nylon, and other polar polymers.

At least one or more of the components of the polymer blends of theinvention can include a substantially crystalline or semicrystallinepolymer. Various embodiments of the invention can include, for example,at least one or more substantially crystalline low molecular weightpolymer component(s). The term “substantially crystalline orsemicrystalline” is understood in the polymer art and as used hereinrefers to a material's inherent ability to crystallize when referring tomaterial type, or alternatively its current state of crystallinity whenreferring to a particular product or object, as determined usingconventional techniques as known in the art. Methods for determining thedegree of crystallinity of a polymer are known in the art and include,for example, DSC, density gradient tubes, and x-ray diffractiontechniques. Generally as used herein, the term crystalline orsemicrystalline refers to materials having a melt peak on DSC with atleast about 5 J/g of material, or more, for example, at least about 10J/g material or more. As non-limiting examples, polyesters cay exhibit amelt peak on DSC of about 30 to about 50 J/g and olefins can exhibit amelt peak on DSC of up to about 100 J/g.

The addition of a substantially crystalline polymer component, includinga low molecular weight substantially crystalline polymer component, canpromote the flow of the polymer blend at low temperatures withoutblocking or fusing. The addition of one or more substantiallycrystalline low molecular weight polymers can, for example, result in ablend having a melting point within about 20° C. of the targeted blendapplication temperature (i.e., the activating temperature, which can be,for example, about 125° C. or less).

In exemplary embodiments of the invention, the low molecular weightcomponent includes a substantially crystalline polymeric ornon-polymeric component (also referred to herein as a substantiallycrystalline plasticizer). In this embodiment of the invention, thesubstantially crystalline low molecular weight component can have a meltpoint (T_(m)) that is higher than the glass transition temperature T_(g)of the higher molecular weight polymer component of the blend. Again,although not wishing to be bound by any explanation of the invention, itis currently believed that the use of such materials in the blend canresult in sharp flow profiles. The polymer blend of this embodiment ofthe invention can be in any of the various forms discussed herein,including fibers, nonwoven fabrics, coatings, and the like. An exemplaryblend in accordance with this embodiment of the invention can includephenoxy having a T_(g) as the high molecular weight component and asubstantially crystalline component (plasticizer) having a T_(m) that ishigher than the T_(g) of the phenoxy component, and the like, includingcombinations thereof.

Each of the components can be present in the polymer blend of theinvention in an amount sufficient to impart the desired wetting andblocking resistance properties thereto. In exemplary embodiments of theinvention, the blend can include at least about 10 percent by weight ofone, or both, of the higher molecular weight and the lower molecularweight components. For example, the polymer blends of the invention caninclude at least about 20 percent by weight, at least about 30 percentby weight, at least about 40 percent by weight, and at least about 45percent by weight, based on the total weight of the polymer blend, ofone or both of the higher and lower molecular weight components.

The skilled artisan will realize that the respective first and secondcomponents of the polymer blends of the invention can include at leastone, or a blend or more than one, component thereof. For example, thefirst component of the polymer blend can include at least about 10weight percent of one polymer or can include at least about 10 weightpercent of a blend of two or more polymers, in accordance with thepresent invention (in which case, the first blend component can includeless than 10 weight percent of a particular polymer of the polymerblend). Similarly, the second component of the polymer blend can includeat least about 10 weight percent of one compound or can include at leastabout 10 weight percent of a blend of two or more such compounds (inwhich case, the second blend component can include less than 10 weightpercent of a particular compound or component thereof). As used herein,the term “compound” in reference to the second blend component caninclude polymeric and non-polymeric compounds.

In embodiments including a blend of polymers as the first blendcomponent, one or more of the polymers can meet one or more of thecriteria of molecular weight, T_(g), etc., as discussed herein.Similarly, in embodiments including a blend of compounds as the secondblend component, one or more of the compounds can meet one or more ofthe criteria of molecular weight, T_(m), etc., as discussed herein.

In other embodiments of the invention, the polymer blend can furtherinclude at least one additive, as discussed herein, in about a 1:1:1ratio high molecular weight polymer component:low molecular weightcomponent:additive, although as discussed herein additives when presentcan be present in amounts outside of this range.

The polymer components, and additives when present, can be present inamounts outside of these ranges as well. Surprisingly, however, theinventors have found that relatively high amounts (at least about 10percent by weight, and more, up to 50 percent) of the low molecularweight component (which can have a melt flow rate in the thousands) canbe included in the polymer blends of the invention without substantiallydecreasing the blocking resistance of the polymer blend and also withoutsignificantly decreasing the processability of the polymer blend.Similarly, the inventors have surprisingly found that the polymer blendscan include relatively high amounts (at least about 10 percent byweight, and more) of the high molecular weight polymer component withoutsignificantly reducing the flow or wetting properties of the blend asdescribed herein.

The polymer components can blended with one another using conventionalmixing techniques. In exemplary embodiments, the polymer components canbe dry blended with one another prior to melting the polymers insubsequent extrusion or other polymer processing steps. In otherexemplary embodiments, separate polymer melts can be combined with oneanother, for example, as polymer melts pass through an extruder.

The polymer blends of the invention can further include at least one, ormore, additives mixed or blended therewith. Such embodiments of theinvention can be useful, for example, as additive delivery systems, asdiscussed in more detail herein. Exemplary additives useful in thepresent invention can include without limitation antimicrobials,biocides, flame retardants, toxic absorbers, conductive agents,abrasives, antioxidants, UV stabilizers, optically active compounds,tracers, plating catalysts, particulates, reinforcing agents, fillers,pigments, talc, glass fibers, clays, silicas, mineral silicates, mica,odor absorbers, nano-particles, chemical deactivators such as activatedcarbon, antistats, markers, counterfeit tracers, fluorescents,fungicides, mildewcides, phosphorescents, reflectants, “smart fabric”components, polytetrafluoroethylene (PTFE), repellants, ointments, andthe like, and combinations thereof. The invention allows the readyapplication of a wide ranging amounts of additives and can beparticularly useful in the application of very low amounts of additives.The invention can be useful for applying a very small amount of additivesubstantially uniformly to a substrate with durability. The resultantlayer can in many instances be just a few microns thick as well so thatthe particle size of the additive can be very small. This can be usefulin many applications in which the additive particles might otherwise beburied below the skin of a synthetic fiber.

For example, silver and/or copper based antimicrobials can be introducedinto a suitable substrate in accordance with the present invention. Suchantimicrobials can be particulate in nature to promote controlledrelease of the active agent yet typically must also be near the surfaceof a substrate (such as a fiber) to function. Typically, a relativelylow amount of the antimicrobial agent can be effective. The presentinvention can allow the introduction of relatively small quantities ofsuch antimicrobial agents into a suitable substrate, such as a surfaceof a fiber, for use in numerous applications, including withoutlimitation health care products such as hospital sheets, gowns,draperies, and mattresses to help control secondary infections; andsports or athletic wear to help reduce odors from bacteria and mildew.More uniform distributions can be achieved by dispersion using such avehicle when the additive level is low, such as but not limited to the0.01 to 0.1% range.

Odor absorbing agents such as activated carbon can also be effectivelyintroduced into a suitable substrate in accordance with the presentinvention. Similar to silver and copper antimicrobial agents,particulate odor absorbing agents can be more effective when held at thesurface of the substrate (such as a fiber surface). The presentinvention can allow the introduction of effective amounts of odorabsorbing agents into a suitable substrate, such as a fiber surface, tohelp in protecting freshness in sportswear, among other applications.

Similarly, nano-particles and other additives useful, for example, inthe deactivation of chemical agents can also be introduced into asuitable substrate in accordance with the present invention. Theresultant products can be useful in military, industrial, and homelandsecurity applications.

Flame retardant agents are another non-limiting example of the types ofactive agents that can be introduced to a suitable substrate inaccordance with the present invention. For example, particles thatexpand when heated to flame temperatures could be used to bolsterintumescent flame retardant systems and could be affixed to fabrics inaccordance with the present invention. The flame retardant particles canalso be a part of multicomponent flame retardant systems such asdiscussed in copending and commonly assigned U.S. application Ser. No.11/369,252, filed Mar. 7, 2006, the entire disclosure of which is herebyincorporated by reference. Non-limiting examples of flame retardantadditives suitable for use in accordance with the present inventioninclude, for example, melamine cyanurate, boric acid and boroncontaining salts, halogens, antimony compounds, ammonium polyphosphate,melamine polyphosphate, phosphorous compounds, hydrates such as aluminumtrihydrate, expanded graphite, char-inducing catalysts, and the like andcombinations thereof.

As yet another non-limiting example, taggant or tracer additives can beadhered to a suitable substrate in accordance with the presentinvention. Such taggant or tracers for fabric, paper and other productscan be useful, for example, to audit the source of fabrics, to helpcontrol counterfeiting, and the like. In other non-limiting examples,many optical markers such as fluorescent or phosphorescent agentstypically function at relatively high concentrations. Using the presentinvention, such agents can be made visible at lower concentrations bythe increased efficiencies of concentrating the agents into localizedregions of a suitable substrate where they are delivered by a polymerblend of the invention.

The present invention is not limited to these applications. Theformulated systems of the invention can have the additional benefit ofhaving inherently low color. This mask surface imperfections of asubstrate to which the polymer blend is applied, such as that on anatural fiber, which in turn can reduce dullness and create a “wetter,”silkier look.

These and other additive(s) can be incorporated into the polymer blendsof the present invention using conventional techniques. The additive(s)can independently blended with one or more of the polymer componentsand/or can be added to the polymer blend. In exemplary embodiments, theadditive(s) can be dry blended with one or more of the polymercomponents of, and/or with the polymer blend itself, prior to meltingthe polymer components and/or the resultant polymer blend in subsequentextrusion or other polymer processing steps. The additive(s) can also beadded to melts of the polymer components and/or of the polymer blend,for example, as the polymer component and/or polymer blend melt(s) passthrough an extruder. A masterbatch of one or more polymer componentsand/or the polymer blend of the invention and the additive(s) can alsobe prepared and added to the polymer components and/or polymer blend indry or melt form. The additive(s) can be used in the invention invarious forms, including powder, liquid and melt forms, as appropriatefor a given application.

Other aspects of the invention include polymeric bonding systems andpolymeric additive delivery systems that include the polymer blends ofthe invention as a component thereof, as well as methods of using thesame. In these and other aspects of the invention, the polymer blendscan be provided in any form useful for a particular end application,including without limitation, in the form of a fibrous material, film(including co-extruded films, permeable films, impermeable films), foam,sheet, coating, a particulate material, and the like, and combinationsthereof.

The polymer blends of the invention can be particularly useful asadditive delivery systems to impart additive functionality to asubstrate, including cotton and other natural fibers. The polymer blendscan be suited for uniformly dispersing and binding particulate additivesto a substrate, durably anchoring the additive to the substrate, forexample via a thin flexible coating, to optimize placement and maximizeperformance. As noted herein, the polymer compositions of the inventioncan have sharp flow profiles with improved flow at lower temperaturesfor bonding. Yet the polymer blends are not tacky or prone to block atnormal extremes of temperature exposure during transporting andwarehousing. The polymer blends can be used to deliver discontinuousdeposits (for example small islands) or a substantially continuous yetbreathable network that coats and bridges the surface layer of thesubstrate (such as the surface of fibers) in a construction. Inaddition, the polymer blend additive systems can exhibit the permanenceof a thermoplastic but can be applied to a substrate at very low levelswith good penetration and dispersion.

As used herein, the term “fibrous material” includes fibrous articlessuch as but not limited to staple fibers, continuous filaments, yarns,tows, fiber bundles, bulked continuous filament (BCF), staple fiber spunyarns, twisted yarns (i.e., 2 or more yarns twisted together), wrappedyarns, sewing thread, meltblown fibers, spunbonded filaments, nowovenfabrics, woven fabrics, knit fabrics, and the like, as well ascombinations thereof. In general, staple, multifilament, and spunbondfibers in accordance with the present invention can have an equivalentdiameter of about 0.5 to about 100 denier. Meltblown filaments can havea diameter of about 1 to about 5 microns. The fibers can also bemonofilaments, which can have a fineness ranging from about 20 to about5,000 denier.

For ease of discussion, the term “fiber” as used herein can refer bothto fibers of finite length, such as conventional staple fiber, as wellas substantially continuous fibrous structures, such as continuousfilaments, unless otherwise indicated. The term fiber as used herein canalso include crimped, uncrimped, and textured fibers and filaments,including bulked continuous filaments (BCF) and filament tows as well.The fibers of the invention can be hollow or non-hollow fibers, andfurther can have a substantially round or circular cross-section ornon-circular cross-section (for example, “shaped fibers” or fibers withshaped cross-sections, such as but not limited to oval fibers,rectangular fibers, multi-lobed or lobal fibers, delta cross-sections,and the like).

When the polymer blends of the invention are in the form of a fiber, thefibers can be monocomponent fibers or multicomponent fibers, in which atleast one, or more, components thereof includes the polymer blend of theinvention. At least one or more components can be dissolvable. Themulticomponent fibers can have a variety of fiber configurations asknown in the art so long as the fiber components are arranged so as toform distinct cross-sectional segments along at least a portion of thelength of the fiber. The multicomponent fibers can include substantiallynon-occluded segments, such as those present in pie/wedge fibers,side-by-side fibers, segmented round fibers, segmented oval fibers,segmented rectangular fibers, segmented multilobal fibers, and the like.The present invention is not limited to non-occluded fiberconstructions, and accordingly other fiber configurations are includedwithin the scope of the present invention, including those in which atleast a portion of a one fiber segment is partially or fully occluded byan adjacent segment, such as found in islands in the sea fiberconstructions, sheath core fibers, and the like. The multicomponentfibers of the invention further can be splittable, i.e., capable ofseparating into microfilaments upon appropriate chemical and/ormechanical action. Alternatively, the multicomponent fibers of theinvention can be substantially nondissociable.

Nonwoven fabrics useful as the fibrous materials of the invention can bemade according to any of the known commercial processes for makingnonwoven fabrics, including processes that use mechanical, electrical,pneumatic, or hydrodynamic means for forming or assembling fibers into aweb, for example carding, wetlaying, air laying, spunbonding,meltblowing, and the like. The webs can be bonded using techniques asknown in the art, such as but not limited to mechanical bonding, such ashydroentanglement and needle punching, adhesive bonding, thermalbonding, and the like, to form a coherent and useful fabric structure.An example of thermal bonding is through-air bonding, although otherthermal bonding techniques, such as calendering, microwave or other RFtreatments can be used. Other textile structures such as but not limitedto woven and knit fabrics and tufted carpets and yarns prepared for usein forming such woven and knit fabrics and tufted carpets are similarlyincluded within the scope of the present invention. Nonwoven-containingarticles similarly include but are not limited to hygiene, safety masks,filter media, footwear components and furniture backing. In tuftedcarpets, the coatings of the invention can be useful in applyingantimicrobials and other consumer pleasing functionalities, as well asimproving tip definition and wear properties.

As used herein, the term “particulate materials” can include a pluralityof particles formed of the polymer blends of the invention. Exemplaryembodiments of the invention include polymer blends in the form offinely reduced powders having average diameter of less than about onemillimeter (mm), and finely divided powder having an average diameter ofless than about 200 microns, for example from about 20 to about 200microns, although the present invention is not so limited andparticulate material having an average diameter outside of these rangescan also be useful in the present invention.

The polymeric additive delivery systems of the invention can furtherinclude one or more additives as a component thereof, as describedherein. The additives can be substantially uniformly mixed with thepolymer blend so that the additive is substantially uniformlydistributed throughout the delivery system (for example, substantiallyuniformly distributed throughout a staple fiber formed of an admixtureof the polymer blend and one or more additives). Alternatively, theadditive can be substantially non-uniformly distributed in the additivedelivery system. As a non-limiting example of this embodiment of thepolymeric delivery systems of the invention, the additive can be presentalong a surface of a fiber formed of the polymer blend, which can resultfrom “blooming” of the additive to the article surface under suitableconditions.

In this aspect of the invention, additives can be delivered within amatrix, such as a fibrous system, even if the polymer blend is notpresent in sufficient quantity to significantly bond the matrix fiberstogether. In this manner, the present invention can provide a mechanismfor introducing an additive into a matrix material by activating theblend and allowing the polymer blend spread out and coat the matrixmaterials. The relatively low flow temperature of the polymer blends ofthe invention may provide the additional advantage of allowing the useof temperature-sensitive additives that might not survive incorporationinto higher melt temperature synthetic fibers.

The polymeric bonding systems and polymeric additive delivery systems inaccordance with these aspects of the invention can be useful in theproduction of various products, including without limitation, fibrousarticles, laminates, composites, and the like, as well as combinationsthereof. The articles of the invention including the polymer blend as acomponent thereof can be generally described as including a matrixmaterial and the polymer blend, per se or in the form of a polymericbonding system, polymeric additive delivery system, or the like, asdescribed herein.

As used herein, the term “matrix material” refers generally to thematerial to which the polymer blend is applied or blended with toachieve bonding, additive delivery or other functional aspects of thepresent invention. In various exemplary embodiments of this aspect ofthe invention, articles including the polymer blends of the inventioncan be referred to generally as “composite articles” to indicate thatthe articles include a combination of two or more materials, includingthe polymer blend of the invention and another material (i.e., thematrix material as defined herein), that differ in form or composition.The constituent components of the composite articles of the inventionmay, but are not required to, retain their identities, be physicallyidentified and exhibit an interface between one another.

Non-limiting examples of the types of matrix materials that may beuseful in the production of the articles of the invention includefibrous materials (including synthetic fibers and natural fibers, suchas plant fibers and animal fibers), cellulosic materials, laminates,composites, polymeric resins, foams, and the like, as well ascombinations thereof. The matrix materials can have different functions,including support, reinforcement, filler, binder, and the like, as wellas combinations of these functions.

Exemplary fibrous materials useful as matrix materials of the compositearticles of the invention include any of the types of fibrous materialsdescribed herein. As an example, the polymer blend (for example in theform of staple fibers or particulate material, optionally in combinationwith an additive) can be applied to and/or intermixed with a pluralityof staple fibers formed of a different polymer composition to form anonwoven web. The staple fibers can include synthetic and/or man-madefibers, natural fibers, and/or blends of the same. Exemplary syntheticfibers include without limitation acrylic fibers, polyolefin fibers,polyester fibers, polyamide fibers, and the like, as well as blendsthereof with one another and/or with natural fibers. Exemplary naturalfibers include without limitation cotton fibers, wool fibers, and thelike, as well as blends thereof with one another and/or with syntheticfibers. Fibrous materials can be utilized separately, furtherincorporated into multilayer constructions such as laminates orcomposites, or be used as coating substrates within the scope of theinvention.

In this embodiment of this aspect of the invention, the resultant webcan be subjected to activation temperature conditions sufficient topromote substantially wetting of the staple fibers or particulatematerial formed of the polymer blend of the invention within the websufficient to bond the staple fibers to form a substantially coherentstructure and/or to distribute an additive within the fabric structure.The present invention can provide an advantageous mechanism for deliveryof an additive, such as an antimicrobial agent, to a fibrous structure,such as a web including a plurality of cotton fibers.

As a non-limiting example, a fiber containing the polymer blend of theinvention in which are imbedded antimicrobial particles (such as silveror copper compounds) is blended with cotton fibers, for example, duringa carding process. The resultant mixture can be heat treated underconditions sufficient to activate the polymer to wet out and coat thecotton fibers and thus deliver the antimicrobial agent within the cottonarticle to provide a cotton article with antimicrobial properties. Thehigh flow of the polymer blend can allow the use of a relatively smallamount of synthetic fiber to treat a larger volume of cotton. Therelatively low activation temperature of the polymer blends can furtheradvantageously minimize discoloration that can occur when heat treatingcotton fibers at relatively high temperatures.

The polymeric bonding systems and/or polymeric additive delivery systemsof the invention can also be useful in the production of other fibrousarticles, including products requiring relatively deep penetration of anadhesive into the article, such as may be the case for many tuft-lockson carpet, scatter rugs, automotive flooring, and the like. Thepolymeric bonding systems and/or polymeric additive delivery systems ofthe invention can also be useful in various hot melt applications, suchas anti-slip coatings on carpets and other flooring materials, which canbenefit from improved flow and sharper flow profiles (and thus fasteroperation in industrial application) as compared to traditional hot meltadhesives. In still other applications, the polymeric bonding systemsand/or polymeric additive delivery systems can be useful as coatings foryarns and other fibrous materials to reduce hairiness, pilling, minimizeyarn pullout, increase strength, and to improve abrasion resistance.

The polymeric bonding systems and/or polymeric additive delivery systemsof the invention can also be useful in the production of other fibrousarticles such as chenille yarns, felt, other wrapped yarns, and thelike. In these types of products, the adhesive delivery system must bondfibers many fiber diameters removed from where the binder is applied,and accordingly flow characteristics can be increasingly important forthe performance of the end product. The present invention can providesuch bonding and further can improve carpet yarn timp definition andwear aesthetics. For example, in the manufacture of chenille yarn,typically twisted pairs of a core yarn hold in place bundles of “effect”yarn at an angle substantially perpendicular to the core yarn. A binderapplied via the core yarn advantageously has enough flow to penetrate toa depth of dozens of fiber diameters, yet stop short of wicking out thelength of the effect yarn and so causing it to stiffen. In oneembodiment of the invention, the polymer blends of the invention can beincorporated as a part of one or more core yarns. The polymer blend maybe incorporated into the core yarn using any suitable techniques, suchas blending fiber formed of the polymer blend with the core yarn,coating the core yarn with the polymer blend, and/or incorporating thepolymer blend as a component in a multicomponent core fiber.

As another non-limiting example, the matrix materials can include any ofthe types of cellulosic materials known in the art, such as but notlimited to wood particles, wood fibers, fluff pulp (such as can be usedin disposable absorbent articles such as diapers), cellulose acetatefibers, cotton, flax, and the like and mixtures thereof, and can beuseful in the production of paper products, including wipes. In thisembodiment of this aspect of the invention, the polymer blend (forexample in the form of staple fibers or particulate material, optionallyin combination with an additive) can be applied to and/or intermixedwith a plurality of wood fibers or particles and the resultant mixturecan be subjected to activation temperature conditions sufficient topromote substantially wetting of the staple fibers or particulatesformed of the polymer blend of the invention within the articlesufficient to bond the wood fibers or wood particles to form asubstantially coherent structure and/or to distribute an additive withinthe coherent structure. In exemplary embodiments, the length scale ofbonding may be limited to that area around neighboring fibers and theflow requirement may be low. The present invention can be helpful insuch application to control the bonding temperature to a desiredprocessing target, and insure good wet-out and bonding. The presentinvention can also be useful for incorporating and/or delivering variousadditives, including additives capable of improving insect resistanceand/or mildew resistance.

As yet another non-limiting example, the invention can include anadditive delivery system including a water soluble additive, such as butnot limited to a water soluble flame retardant. The polymer additivesystem of this embodiment of the invention can further include a polymerblend of the invention, which can be in any suitable form, for example,as a plurality of fine particles. The additive delivery system inaccordance with this embodiment of the invention can be useful inemulsion type coatings, such as acrylic coatings. As a non-limitingexample, the additive delivery system can be a waterborne coating systemincluding include a water soluble additive, such as a water solubleflame retardant, encapsulated in a plurality of emulsified particlesformed of the polymer blend of the invention. In various embodimentsincluding a water soluble flame retardant additive, the additivedelivery system may not see melt conditions until exposed to flameconditions (as contrasted to the manufacturing process), and theadditive can thus be dispersed when an article on which the coating isapplied is exposed to flame conditions and burns. Otherwise, theadditive may still be “locked up” in the particles embedded in thecoating. The invention can also be useful as a part of a A-B type duallayer coating (base and top coating) or A-B film system, in which Aincludes at least one flame retardant component and B includes anotherflame retardant component.

The blend of the invention can be present in the composite articles invarying amounts, depending upon various factors, such as the applicationof the resultant product, desired degree of bonding, aesthetics, and thelike and can be readily determined by the skilled artisan. Generally,the polymer blend in the form of fibers, particulates, etc. can bepresent in the composite article in an amount ranging from about 1 toabout 25 percent by weight, although the polymer blend can be present inamounts outside of this range as well.

In these and other embodiments of this aspect of the invention, theblend in the form of staple fibers, particulate material, and the like,can be applied to and/or mixed with a desired matrix material, and theresultant mixture can be subjected to a suitable activation temperatureto activate wet out of the binder fibers and/or particulate materials.Although the polymer bonding system of the invention has been describedherein with reference to staple fibers and particulate materials, thepresent invention is not so limited, and as indicated herein, thepolymer bonding systems can also be in other forms such as a coating(for example one or more extrusion coated layers) applied to an articleto bonded, as a film, sheet material, and the like.

Yet another aspect, the present invention includes activatable yarns. Inthis aspect of the invention, yarns formed of a suitable polymer,typically with limited reactivity such as many polyolefins andpolyesters, can include a functionalized additive, typically having alower molecular weight that the polymer of the yarn. The polymer andfunctionalized additive of the activatable yarns can each be present inthe yarn in amounts of at least about 10 percent by weight, at leastabout 20 percent by weight, at least about 30 percent by weight, atleast about 40 percent by weight, and up to at least about 50 percent byweight, and higher, based on the total weight of the yarn. The yarn canfurther include other additives such as those discussed herein inamounts also as discussed herein.

The functionalized additive can act as an “activating agent” to promoteadhesion of the yarn and can be selected based at least in part upon thenature of an adhesive to be used with the yarn. The functionalizedadditive can be incorporated into the polyolefin or polyester yarn usingany suitable technique, such as blending fiber formed of thefunctionalized additive with the yarn, coating the yarn with thefunctionalized additive, and/or incorporating the functionalizedadditive as a component in a multicomponent fiber. The functionalizedadditive can be incorporated into other synthetic polymers, suchpolyamides and modified celluloses.

A non-limiting example of an activatable yarn in accordance with thisaspect of the invention includes a polyolefin or a polyester yarn havinga maleic anhydride modified polyolefin incorporated therein. Activationof the maleic anhydride modified polyolefin can promote bonding of thepolyolefin and/or polyester yarn using a nylon-based adhesive. Anothernon-limiting example of an activatable yarn in accordance with thisaspect of the invention includes a polyolefin or polyester yarn havingan amine functionalized additive, such as stearamide, incorporatedtherein as the functionalizing additive. Activation of the stearamidecan promote bonding of the yarn using an acid functional binder.

The present invention will be further illustrated by the followingnon-limiting examples.

COMPARATIVE EXAMPLE

Several samples of ethylene methacrylate (EMAC) adhesive polymers havingdifferent molecular weights are evaluated to try to develop improvedflow for better wet-out. The materials are tacky and block badly, evenat molecular weights that still are not low enough to flow at asignificantly reduced temperature.

COMPARATIVE EXAMPLE

A maleated polypropylene wax such as that commercially available fromEastman Chemical as Epolene E-43 is blended in amount of 5 to 10% into apolyethylene or polypropylene resin. This material can be spun, themaleic acid functionality can provide adhesive properties, and the blendcan provide a binder for applications requiring little flow. The bulkand rheological properties of the blend, however, remain that of thedominant polymer.

COMPARATIVE EXAMPLE

A high molecular weight maleated polyethylene such as that commerciallyavailable from Eastman Chemical as Epolene G-2608 is blended inapproximately equal amounts with a common polyethylene resin. Thismaterial retains the strength and flow characteristics of itsconstituents, i.e., they fall within the range of what can normally befound with differing grades of polyethylene. With these blends, theformulator achieves intermediate levels of acid functionality sufficientfor bonding other polar fibers while reducing cost. Nonetheless, hightemperatures (>180° C.) and/or pressures (calendering) are stillrequired for bonding to take place.

EXAMPLE 1 (INVENTION)

45% of a high molecular weight maleated polyethylene (such as thatcommercially available from Eastman Chemical as Epolene G-2608) isblended with 55% of a common paraffin (such as that commerciallyavailable as IGI 1230). The resulting blend exhibits sufficient meltstrength for fiber spinning and further bonds (without pressure) toacrylic at 120° C., which is a 60° C. drop from the temperature requiredof G-2608 alone. The mixture does not exhibit blocking on the packageeven when held at temperatures above the melting point of the paraffin.

EXAMPLE 2 (INVENTION)

50% of a maleated polypropylene wax (such as Eastman's Epolene C-18) isblended with 50% of a common paraffin (IGI 1230). This material iscoated onto acrylic yarn and incorporated into chenille yarn. The blendbonds in boiling water baths typical of dying processes, yet does notexhibit blocking problems upon shipping. Improved wear resistance of thechenille is achieved at normal use temperatures in such applications asautomotive upholstery. This example exemplifies a “100° C. flow system”as discussed herein and is illustrated in FIGS. 1, 3A-B and 4A-C. Inthis example, the paraffin component alone exhibits blocking and nofunctionality for wet-out. The Epolene wax exhibits too high a meltingpoint to flow at the desired temperatures. The blend can be useful as acoating onto a yarn and as a core of a chenille yarn. The blend canpenetrate readily into an effect yarn (such as an acrylic or cottoneffect yarn) at about 100° C. (a temperature sufficient to drive offwater) and can bind it in place for improved wear resistance. When anadditive is blended in the polymer blend, the blend can be reduced to apowder. The powder can be sprinkled onto cotton and made to flow atabout 100° C., creating an extremely thin coating over the cotton andbinding the additive to the cotton.

EXAMPLE 3 (INVENTION)

A low molecular weight maleated polyethylene or polypropylene wax, suchas those commercially available from Eastman Chemical under the tradename Epolene, is blended with a high molecular weight polyethylene ormodified polypropylene to gives results similar to that exhibited by theblend of Example 2. The blend exhibits high flow yet good fiber-formingproperties at remarkably low temperatures, and at the same time goodintegrity in uncontrolled storage conditions. This example exemplifies a“150° C. flow system” as discussed herein and is illustrated in FIGS. 2Aand 2B. In this example, the polyethylene alone exhibits poor flow atthis temperature and no functionality. The Epolene wax has too low aviscosity/melt strength to be spun into fibers. The blend may be usefulspun as the sheath of a bicomponent filaments yarn and the yarn can beused as the core of a chenille yarn, When heated in an autoclave, thebonder can readily penetrate into the effect yarn and hold it in placefor improved wear resistance.

EXAMPLE 4 (INVENTION)

A binder/additive delivery system of the invention can be provided fordelivery of a hard-coat to a sheet product, such as polyester glazing.Suitable additives useful in this application include without limitationrigid flake products, such as glass flake, mica, and the like, andmixtures thereof. Mica flake can be more economically feasible thanglass and further its functionality can contribute to good wet-out. Inthis example, a 1:1:1 mixture of paraffin, maleated polypropylene (PP)wax, and mica flake is prepared and applied to a sheet product, forexample by sprinkling, spraying, foaming or other suitable techniques. Amild heat-treatment (steam or hot air gun) allows the blend to uniformlycover the surface of the product, wet out for optical clarity, andpresent the hard mica flake for wear and abrasion resistance. Abradedsurfaces can be repaired/reflowed by additional heat-treatment, with orwithout the addition of more of the mixture. To improve adhesion, theglazing can have polar functionality to react with the acid in the wax.This can be accomplished, for example in the case of polyester glazing,by incorporating a tie layer of a bonding material such as a phenoxyresin, or by including an additive in the polyester itself, again suchas phenoxy.

EXAMPLE 5 (INVENTION)

Phenoxy polymer (MW about 20,000) is an amorphous polymer used as abinder in composite automotive structures such as headliners. The Tg isabout 90° C. and is important to preventing creep at elevatedtemperatures of an automotive interior. The high molecular weight limitsits ability to flow and wet out a fibrous mat. The lack of crystallinitymakes it difficult to spin into a fiber form, since it does notstrain-harden.

When blended with pentaerythritol tetrabenzoate (PETB, sold as Uniplex552 by Unitex Chemical Co.), non-polymeric MW=552, Tm=104° C. at 10-25%,the phenoxy blend flows much more readily when molded in a headliner,giving superior wet-out. PETB is an example of a substantiallycrystalline plasticizer, which in the invention as discussed herein hasa Tm that is greater than the Tg of the phenoxy. The improvedflowability also allows spinning into a fiber form, either as a filamentyarn or as a non-woven, in part because the melt now increases inmodulus more when oriented (much like solution spinning). Normally onewould expect that such a plasticizer reduces Tg, which it does by asmuch as 25° C. However, because the PETB has a crystalline melt pointhigher than the Tg of the phenoxy, the mixture in fact shows a cold-flowpoint higher than the Tg of the unmodified phenoxy. Thus it continues tobe useful as a binder in elevated temperature environments, does notcreep excessively or become tacky as might be predicted by the Tg.

Example 1 of the invention above is similar to Example 5 in principle.The high molecular weight maleated polyethylene is a desirable binder,yet will not flow well at temperatures cotton will survive withoutdiscoloring. Adding (crystalline) paraffin improves flow without makingthe blend tacky.

EXAMPLE 6 (INVENTION)

Polypropylene is spun into synthetic fibers using a low level of polarfunctional additive, which comes to the surface. The polar functionaladditive can be, for example, an ionomer, PVOH, or the like. The maleicacid functional binders then wet the polypropylene fiber spontaneously,where previously polypropylene fiber is difficult to adhere to.

Various exemplary polymer blends of the invention are prepared andapplied to a fibrous substrate to evaluate the flow properties thereof.FIGS. 1-4 are photomicrographs illustrating various behaviorcharacteristics of exemplary polymer blends of the invention.

FIG. 1 is a photomicrograph of particles formed of an exemplary polymerblend of the invention, which blend can have an activating temperatureof about 100° C. (a“100° C. Flow” system). The photomicrographillustrates that the polymer blend material can be friable and treatedto form a characteristic grain size under suitable conditions. Thematerial of FIG. 1, for example, includes particles of about 50 microns(2 mils) and larger particles show sharp features and internal crackingwith this same length scale. This indicates that the polymer blendmaterials of the invention, such as the illustrated 100° C. flowmaterial, can be reduced to a substantially stable powder, including 50um powder, using suitable treatments as known in the art.

FIGS. 2A and 2B are photomicrographs illustrating the ability ofexemplary high flow temperature blends of the invention to suitablypenetrate a fibrous substrate, for example, the strong thermodynamicdrive for the polymer blend (binder) of the invention to penetrate acotton fabric. In particular, FIGS. 2A and 2B are micrographs of a “150°C. Flow” system applied to a cotton substrate. FIG. 2A is aphotomicrograph of the back of a cotton fabric to which a polymer blendhaving an activating temperature of about 150° C. is applied after 11minutes at 125° C., and FIG. 2B is a photomicrograph of a cotton fabricto which a polymer blend having an activating temperature of about 150°C. is applied after 50 minutes at 150° C. In this example, even anunreduced (3 mm) pellet of a polymer blend having an activatingtemperature of about 150° C. can flow into a cotton fabric. Thephotomicrographs demonstrate that after just 11 minutes at 125° C., thepellets have become droplets and wet through to the back of the fabric.With higher heat and longer exposure, the droplets can be absorbedcompletely. In contrast, the polymer blend system of FIG. 1 (the “100°C. Flow” system) would be expected to look like the micrograph of FIG.2B substantially as soon as it was brought to temperature. A finerdispersion of powder would be expected to provide thin, uniformcoverage.

FIGS. 3A and 3B are photomicrographs illustrating the loading of roughlyground pellets formed of an exemplary polymer blend of the inventionhaving an activating temperature of about 100° C. on a cotton fabric.The inserted text gives dimensions of the largest droplets. Good contactangles are observed yet large droplets approximating the original sizerange of the polymer blend particles as applied to the substrate remain.Far less mass was found under the microscope, however, than was added, aphenomenon clarified in FIGS. 4A-C, discussed below.

FIGS. 4A, 4B and 4C are higher resolution photomicrographs of thepolymer blend of the invention of FIGS. 3A and B as applied to a cottonsubstrate and demonstrate polymer droplet wicking (rather thanelongating) down a fiber surface to form thin flexible coating layers.Following fiber saturation in a given area of the fabric, wicking ceasesand the droplets seen in FIGS. 3A and B remain at a stable size.However, if the fabric is compressed and unsaturated fibers come incontact with the droplets (or saturated fibers) during heat exposure,the flow will continue until the droplet reservoir is depleted.

The photomicrographs generally illustrate various behaviors of exemplarypolymer blends in accordance with the present invention that make suchsystems useful vehicles for additive delivery. As non-limiting examples,pellets of the polymer blends can be reduced down to at least 50 micronparticle size, with smaller additive particles suspended in them. Thepolymer blends can be dispersed onto the surface of a fabric by simpleslurry or foaming methods. Once heated to activation temperature, thepolymer blends can melt and flow along the fabric surfaces and throughthe fabric interstices, thereby forming thin layers on the surface ofthe fibers, and carrying the additive particles with them. Theseparticles can thereafter be thinly encapsulated and well adhered to thenatural fiber matrix.

Many modifications and other embodiments of the invention will come tomind to one skilled in the art to which this invention pertains havingthe benefit of the teachings presented in the foregoing descriptions.Therefore, it is to be understood that the invention is not to belimited to the specific embodiments disclosed and that modifications andother embodiments are intended to be included within the scope of theappended claims. Although specific terms are employed herein, they areused in a generic and descriptive sense only and not for purposes oflimitation, the scope of the invention being defined in the claims.

1. A polymer blend capable of substantially wetting out a surface at aflow activating temperature without requiring the application ofsubstantial pressure, said polymer blend further having blockingresistance properties, said polymer blend comprising: at least about 10percent by weight, based on the total weight of the polymer blend, of afirst blend component comprising at least one polymer having a firstmolecular weight; and at least about 10 percent by weight, based on thetotal weight of the polymer blend, of a second blend componentcomprising at least one compound having a second molecular weight thatis less than the first molecular weight of the at least one polymer ofthe first blend component, wherein the first molecular weight of the atleast one polymer of said first blend component is sufficiently high toprevent the substantial wet out without the application of substantialpressure of the at least one polymer of the first blend component atsaid activating temperature, and wherein the second molecular weight ofthe at least one compound of said second blend component is sufficientlylow so that the at least one compound of the second blend componentexhibits sufficiently high molecular mobility to substantially preventprocessing of the at least one compound of the second blend componentalone.
 2. The polymer blend of claim 1, wherein said blend comprises atleast about 20 percent by weight of the first blend component.
 3. Thepolymer blend of claim 2, wherein said blend comprises at least about 30percent by weight of the first blend component.
 4. The polymer blend ofclaim 1, wherein said blend comprises at least about 20 percent byweight of the second blend component.
 5. The polymer blend of claim 4,wherein said blend comprises at least about 30 percent by weight of thesecond blend component.
 6. The polymer blend of claim 1, wherein thepolymer blend substantially wets out a surface without requiring theapplication of substantial pressure in about one hour or less at saidactivating temperature.
 7. The polymer blend of claim 6, wherein thepolymer blend substantially wets out a surface without requiring theapplication of substantial pressure in about two minutes or less at saidactivating temperature.
 8. The polymer blend of claim 6, wherein saidactivating temperature comprises a temperature of about 150° C. or less.9. The polymer blend of claim 8, wherein said activating temperature iscomprises a temperature ranging from about 100° C. to about 150° C. 10.The polymer blend of claim 8, wherein said activating temperature iscomprises a temperature of about 100° C.
 11. The polymer blend of claim8, wherein said activating temperature is comprises a temperature ofabout 125° C.
 12. The polymer blend of claim 6, wherein said activatingtemperature is comprises a temperature of about 150° C. or higher. 13.The polymer blend of claim 1, wherein the first blend componentcomprises at least one polymer having a molecular weight at least aboutthree times higher than the molecular weight of the at least onecompound of the second blend component.
 14. The polymer blend of claim13, wherein the first blend component comprises at least one polymerhaving a molecular weight at least about five times higher than themolecular weight of the at least one compound of the second blendcomponent.
 15. The polymer blend of claim 1, wherein the secondcomponent comprises at least one compound having a number averagemolecular weight of about 6000 or less.
 16. The polymer blend of claim1, wherein the first blend component comprises at least one polymerhaving a first melt flow rate and the second blend component comprisesat least one compound having a second melt flow rate that is greaterthan the melt flow rate of the at least one polymer of the first blendcomponent.
 17. The polymer blend of claim 16, wherein the second blendcomponent comprises at least one compound having a melt flow rate of atleast about five times greater than the melt flow rate of the at leastone polymer of the first blend component.
 18. The polymer blend of claim17, wherein the second blend component comprises at least one compoundhaving a melt flow rate of at least about ten times greater than themelt flow rate of the at least one polymer of the first blend component.19. The polymer blend of claim 18, wherein the first blend componentcomprises at least one polymer having a melt flow rate of about 1 orless and the second blend component comprises at least one compoundhaving a melt flow rate of about 100 or more.
 20. The polymer blend ofclaim 1, wherein said polymer blend comprises at least one polymerselected from the group consisting of polyolefins, polyesters, acrylics,polyamides, elastomeric polymers, polyacrylonitrile, acetals,fluoropolymers, epoxies, phenoxies, vinyl alcohol polymers,polyesterimides, polyhydroxyl alkanoates (PHA), polysulfone,polyetheretherketone, cellulose acetate, rayons, biopolymers,polyurethanes, hot melt adhesives, and copolymers, terpolymers andionomers thereof, and combinations thereof.
 21. The polymer blend ofclaim 20, wherein said polymer blend comprises at least one elastomericpolymer.
 22. The polymer blend of claim 1, wherein the second blendcomponent comprises a substantially crystalline or semicrystallinepolymer.
 23. The polymer blend of claim 22, wherein the first blendcomponent comprises at least one polymer having a glass transitiontemperature (T_(g)) and wherein the substantially crystalline orsemicrystalline polymer has a melting point that is greater than theT_(g) of the at least one polymer of the first blend component.
 24. Thepolymer blend of claim 20, wherein at least one of the first and secondblend components comprises a functionalized polymer.
 25. The polymerblend of claim 1, wherein at least one of the first and second blendcomponents comprises a polyolefin.
 26. The polymer blend of claim 25,wherein both of the first and the second blend components comprise apolyolefin.
 27. The polymer blend of claim 25, wherein the polyolefin isselected from the group consisting of polypropylene, polyethylene,polybutylene, and copolymers, terpolymers, and combinations thereof. 28.The polymer blend of claim 25, wherein the polyolefin is functionalized.29. The polymer blend of claim 25, wherein the polyolefin iselastomeric.
 30. The polymer blend of claim 28, wherein the polyolefinis functionalized by reaction with at least one unsaturated anhydride,unsaturated acid or unsaturated ester.
 31. The polymer blend of claim30, wherein the polyolefin is modified by reaction with at least oneunsaturated anhydride, unsaturated acid or unsaturated ester selectedfrom the group consisting of maleic anhydride, citraconic anhydride,itaconic anhydride, glutaconic anhydride, 2,3-dimethylmaleic anhydride,maleic acid, fumaric acid, citraconic acid, itaconic acid, mesaconicacid, glutaconic acid, acrylic acid, methacrylic acid, crotonic acid,2-pentenoic acid, 2-methyl-2-pentenoic acid, dimethyl malcate, diethylmaleatc, di-n-propyl malcate, diisopropyl maleate, dimethyl fumarate,diethyl fumarate, di-n-propyl fumarate, di-isopropyl maleate, dimethylitaconate, methyl acrylate, ethyl acrylate, methyl methacrylate, ethylmethacrylate, methyl crotonate, and ethyl crotonate.
 32. The polymerblend of claim 31, wherein the polyolefin comprises a maleic anhydridemodified polyolefin.
 33. The polymer blend of claim 27, wherein saidpolymer is functionalized by oxidation.
 34. The polymer blend of claim1, further comprising at least one additive.
 35. The polymer blend ofclaim 34, wherein said at least one additive comprises an additiveselected from the group consisting of antimicrobials, biocides, flameretardants, toxic absorbers, conductive agents, abrasives, antioxidants,UV stabilizers, optically active compounds, tracers, plating catalysts,fungicides, mildewcides, phosphorescents, reflectants, smart fabriccomponents, polytetrafluoroethylene (PTFE), repellants, particulates,reinforcing agents, fillers, pigments, talc, glass fibers, clays,silicas, mineral silicates, mica, odor absorbers, nano-particles,chemical deactivators, antistats, markers, counterfeit tracers,fluorescents, ointments, and combinations thereof.
 36. The polymer blendof claim 26, wherein at least one of said first or second componentscomprises a maleic anhydride modified polyolefin, said second componentcomprises a substantially crystalline polyolefin, and said blend has amelting point within 20° C. of the flow activation temperature of theblend.
 37. A polymer blend capable of substantially wetting out asurface at a flow activating temperature without requiring theapplication of substantial pressure, said polymer blend further havingblocking resistance properties, said polymer blend comprising at leastone polymer having a first molecular weight and a glass transitiontemperature T_(g), and a substantially crystalline compound having asecond molecular weight that is less than the first molecular weight ofthe at least one polymer and having a melting point that is greater thanthe T_(g) of the at least one polymer.
 38. The polymer blend of claim37, wherein said blend comprises a functionalized polyolefin.
 39. Thepolymer blend of claim 38, wherein the functionalized polyolefincomprises a maleic anhydride modified polyolefin.
 40. The polymer blendof claim 37, wherein said blend comprises an elastomeric polyolefin. 41.A polymer blend capable of substantially wetting out a surface at a flowactivating temperature without requiring the application of substantialpressure, said polymer blend further having blocking resistanceproperties, said polymer blend comprising a phenoxy having a firstmolecular weight and a glass transition temperature T_(g); and asubstantially crystalline plasticizer having a second molecular weightthat is less than the first molecular weight of the phenoxy and having amelting point that is greater than the T_(g) of the phenoxy.
 42. Anarticle comprising the polymer blend of claim 41, wherein said articleis selected from the group consisting of fibers, nonwoven fabrics,permeable films, impermeable films, foams, and coatings.
 43. A polymericbonding system, comprising: an article comprising a polymer blendcapable of substantially wetting out a surface at a flow activatingtemperature without requiring the application of substantial pressure,said polymer blend further having blocking resistance properties, saidpolymer blend comprising at least about 10 percent by weight, based onthe total weight of the polymer blend, of a first blend componentcomprising at least one polymer having a first molecular weight and atleast about 10 percent by weight, based on the total weight of thepolymer blend, of a second blend component comprising at least onecompound having a second molecular weight that is less than the firstmolecular weight of the at least one polymer of the first blendcomponent, wherein the first molecular weight of the at least onepolymer of said first blend component is sufficiently high to preventthe substantial wet out without the application of substantial pressureof the at least one polymer of the first blend component at saidactivating temperature, and wherein the second molecular weight of theat least one compound of said second blend component is sufficiently lowso that the at least one compound of the second blend component exhibitssufficiently high molecular mobility to substantially prevent processingthe at least one compound of the second blend component alone.
 44. Thepolymeric bonding system of claim 43, wherein the polymeric bondingsystem is in the form of an article selected from the group consistingof fibrous materials, films, foams, coatings, particulate materials, andcombinations thereof.
 45. A polymeric bonding system, comprising: anarticle comprising a polymer blend capable of substantially wetting outa surface at a flow activating temperature without requiring theapplication of substantial pressure, said polymer blend further havingblocking resistance properties, said polymer blend comprising at leastone polymer having a first molecular weight and a glass transitiontemperature T_(g), and at least one substantially crystalline compoundhaving a second molecular weight that is less than the first molecularweight of the at least one polymer and having a melting point that isgreater than the T_(g) of the at least one polymer.
 46. A polymericdelivery system, comprising: a polymer blend capable of substantiallywetting out a surface at a flow activating temperature without requiringthe application of substantial pressure, said polymer blend furtherhaving blocking resistance properties, said polymer blend comprising atleast about 10 percent by weight, based on the total weight of thepolymer blend, of a first blend component comprising at least onepolymer having a first molecular weight and at least about 10 percent byweight, based on the total weight of the polymer blend, of a secondblend component comprising at least one compound having a secondmolecular weight that is less than the first molecular weight of the atleast one polymer of the first blend component, wherein the firstmolecular weight of the at least one polymer of said first blendcomponent is sufficiently high to prevent the substantial wet outwithout the application of substantial pressure of the at least onepolymer of the first blend component at said activating temperature, andwherein the second molecular weight of the at least one compound of saidsecond blend component is sufficiently low so that the at least onecompound of said second blend component exhibits sufficiently highmolecular mobility to substantially prevent processing the at least onecompound of said second blend component alone; and at least oneadditive.
 47. The polymeric delivery system of claim 46, wherein thepolymeric delivery system is in the form of an article selected from thegroup consisting of fibrous materials, films, foams, coatings,particulate materials, and combinations thereof.
 48. The polymericdelivery system of claim 47, wherein the polymeric delivery systemcomprises a fibrous material.
 49. The polymeric delivery system of claim48, wherein the fibrous material is selected from the group consistingof continuous filaments, staple fibers, yarns, tows, meltblown fibers,and spunbonded filaments.
 50. The polymeric delivery system of claim 47,wherein the polymeric delivery system comprises a particulate material.51. The polymeric delivery system of claim 50, wherein the particulatematerial comprises a powder having an average diameter of less thanabout 1 millimeter (mm).
 52. The polymeric delivery system of claim 50,wherein the particulate materials comprises a powder having an averagediameter of less than about 200 microns.
 53. The polymeric deliverysystem of claim 46, wherein the at least one additive comprises anadditive selected from the group consisting of antimicrobials, biocides,flame retardants, toxic absorbers, conductive agents, abrasives,antioxidants, UV stabilizers, optically active compounds, tracers,plating catalysts, fungicides, mildewcides, phosphorescents,reflectants, smart fabric components, polytetrafluoroethylene (PTFE),repellants, particulates, reinforcing agents, fillers, pigments, talc,glass fibers, clays, silicas, mineral silicates, mica, odor absorbers,nano-particles, chemical deactivators, antistats, markers, counterfeittracers, fluorescents, ointments, and combinations thereof.
 54. Apolymeric delivery system, comprising: a polymer blend capable ofsubstantially wetting out a surface at a flow activating temperaturewithout requiring the application of substantial pressure, said polymerblend further having blocking resistance properties, said polymer blendcomprising at least one polymer having a first molecular weight and aglass transition temperature T_(g), and at least one substantiallycrystalline compound having a second molecular weight that is less thanthe first molecular weight of the at least one polymer and having amelting point that is greater than the T_(g) of the at least onepolymer; and at least one additive.
 55. A composite article comprising:a matrix material; and a polymer blend capable of substantially wettingout a surface of the matrix material at a flow activating temperaturewithout requiring the application of substantial pressure, said polymerblend further having blocking resistance properties, said polymer blendcomprising at least about 10 percent by weight, based on the totalweight of the polymer blend, of a first blend component comprising atleast one polymer having a first molecular weight and at least about 10percent by weight, based on the total weight of the polymer blend, of asecond blend component comprising at least one compound having a secondmolecular weight that is less than the first molecular weight of the atleast one polymer of the first blend component, wherein the firstmolecular weight of the at least one polymer of said first blendcomponent is sufficiently high to prevent the substantial wet outwithout the application of substantial pressure of the at least onepolymer of the first blend component at said activating temperature, andwherein the second molecular weight of the at least one compound of saidsecond blend component is sufficiently low so that the at least onecompound of the second blend component exhibits sufficiently highmolecular mobility to substantially prevent processing the at least onecompound of the second blend component alone.
 56. The composite articleof claim 55, wherein the matrix material is selected from the groupconsisting of fibrous materials, cellulosic materials, and combinationsthereof.
 57. The composite article of claim 56, wherein the matrixmaterial comprises a fibrous material selected from the group consistingof synthetic fibrous materials, natural fibrous materials, andcombinations thereof.
 58. The composite article of claim 57, wherein thenatural fibrous material comprises cotton fibers.
 59. The compositearticle of claim 58, further comprising an antimicrobial agent.
 60. Thecomposite article of claim 56, wherein the matrix material comprises acellulosic material selected from the group consisting of cellulosicfibrous materials, cellulosic particles, and combinations thereof 61.The composite article of claim 55, wherein the polymer blend is in theform of an article selected from the group consisting of fibrousmaterials, films, foams, coatings, particulate materials, andcombinations thereof.
 62. The composite article of claim 55, wherein thepolymer blend further comprises an additive.
 63. A composite articlecomprising: a matrix material; and a polymer blend capable ofsubstantially wetting out a surface at a flow activating temperaturewithout requiring the application of substantial pressure, said polymerblend further having blocking resistance properties, said polymer blendcomprising at least one polymer having a first molecular weight and aglass transition temperature T_(g), and at least one substantiallycrystalline compound having a second molecular weight that is less thanthe first molecular weight of the at least one polymer and having amelting point that is greater than the T_(g) of the at least onepolymer.
 64. A chenille yarn comprising at least one core yarn and atleast one effect yarn, wherein said core yarn comprises a polymer blendcapable of substantially wetting out a surface at a flow activatingtemperature without requiring the application of substantial pressure,said polymer blend further having blocking resistance properties, saidpolymer blend comprising a first blend component comprising at least onepolymer having a first molecular weight and a second blend componentcomprising at least one compound having a second molecular weight thatis less than the first molecular weight of the at least one polymer ofthe first blend component, wherein the first molecular weight of the atleast one polymer of said first blend component is sufficiently high toprevent the substantial wet out without the application of substantialpressure of the at least one polymer of the first blend component atsaid activating temperature, and wherein the second molecular weight ofsaid at least one compound of the second blend component is sufficientlylow so that the at least one compound of the second blend componentexhibits sufficiently high molecular mobility to substantially preventprocessing the at least one compound of the second blend componentalone, wherein said effect yarn is bound by said polymer blend of saidcore yarn.
 65. The chenille yarn of claim 64, wherein said polymer blendis present in the form of one or more fibers blended with said coreyarn.
 66. The chenille yarn of claim 64, wherein said core yarncomprises a coating formed of said polymer blend.
 67. The chenille yarnof claim 64, wherein said core yarn comprises a multicomponent fibercomprising at least one component formed of said polymer blend.
 68. Apolymer additive system comprising a water soluble additive and aplurality of particles formed of a polymer blend capable ofsubstantially wetting out a surface at a flow activating temperaturewithout requiring the application of substantial pressure, said polymerblend further having blocking resistance properties, said polymer blendcomprising a first blend component comprising at least one polymerhaving a first molecular weight and a second blend component comprisingat least one compound having a second molecular weight that is less thanthe first molecular weight of the at least one polymer of the firstblend component, wherein the first molecular weight of the at least onepolymer of said first blend component is sufficiently high to preventthe substantial wet out without the application of substantial pressureof the at least one polymer of the first blend component at saidactivating temperature, and wherein the second molecular weight of theat least one compound of said second blend component is sufficiently lowso that the at least one compound of the second blend component exhibitssufficiently high molecular mobility to substantially prevent processingthe at least one compound of the second blend component alone.
 69. Thepolymer additive system of claim 68, wherein said water soluble additivecomprises a flame retardant additive.
 70. A waterborne coating systemcomprising a water soluble additive encapsulated in a plurality ofemulsified particles comprising a polymer blend, wherein said polymerblend comprises a first blend component comprising at least one polymerhaving a first molecular weight and a second blend component comprisingat least one compound having a second molecular weight that is less thanthe first molecular weight of the at least one polymer of the firstblend component, wherein the first molecular weight of the at least onepolymer of said first blend component is sufficiently high to preventthe substantial wet out without the application of substantial pressureof the at least one polymer of the first blend component at saidactivating temperature, and wherein the second molecular weight of theat least one compound of said second blend component is sufficiently lowso that the at least one compound of the second blend component exhibitssufficiently high molecular mobility to substantially prevent processingthe at least one compound of the second blend component alone.
 71. Amethod of bonding an article, comprising activating a polymer blendapplied to an article to be bonded at a flow activating temperaturesufficient to substantially wet out a surface of the article to bebonded with the polymer blend at said activating temperature without theapplication of substantial pressure, wherein said polymer blend hasblocking resistance properties and comprises at least about 10 percentby weight, based on the total weight of the polymer blend, of a firstblend component comprising at least one polymer having a first molecularweight and at least about 10 percent by weight, based on the totalweight of the polymer blend, of a second blend component comprising atleast one compound having a second molecular weight that is less thanthe first molecular weight of the at least one polymer of the firstblend component, wherein the first molecular weight of the at least onepolymer of said first blend component is sufficiently high to preventthe substantial wet out without the application of substantial pressureof the at least one polymer of the first blend component at saidactivating temperature, and wherein the second molecular weight of theat least one compound of said second blend component is sufficiently lowso that the at least one compound of the second blend component exhibitssufficiently high molecular mobility to substantially prevent processingthe at least one compound of the second blend component alone.
 72. Amethod of bonding an article, comprising activating a polymer blendapplied to an article to be bonded at a flow activating temperaturesufficient to substantially wet out a surface of the article to bebonded with the polymer blend at said activating temperature without theapplication of substantial pressure, wherein said polymer blendcomprises at least one polymer having a first molecular weight and aglass transition temperature T_(g), and at least one substantiallycrystalline compound having a second molecular weight that is less thanthe first molecular weight of the at least one polymer and having amelting point that is greater than the T_(g) of the at least onepolymer.
 73. A method of delivering an additive to an article,comprising activating a polymer blend comprising an additive to bedelivered at a flow activating temperature sufficient to substantiallywet out a surface of an article to which the additive is to be deliveredat said activating temperature without requiring the application ofsubstantial pressure to effectively deliver the additive to the article,wherein said polymer blend has blocking resistance properties andcomprises at least about 10 percent by weight, based on the total weightof the polymer blend, of a first blend component comprising at least onepolymer having a first molecular weight and at least about 10 percent byweight, based on the total weight of the polymer blend, of a secondblend component comprising at least one compound having a secondmolecular weight that is less than the first molecular weight of the atleast one polymer of the first blend component, wherein the firstmolecular weight of the at least one polymer of said first blendcomponent is sufficiently high to prevent the substantial wet outwithout the application of substantial pressure of the at least onepolymer of the first blend component at said activating temperature, andwherein the second molecular weight of the at least one compound of saidsecond blend component is sufficiently low so that the at least onecompound of the second blend component exhibits sufficiently highmolecular mobility to substantially prevent processing of the at leastone compound of the second blend component alone.
 74. A method ofdelivering an additive to an article, comprising activating a polymerblend comprising an additive to be delivered at a flow activatingtemperature sufficient to substantially wet out a surface of an articleto which the additive is to be delivered at said activating temperaturewithout requiring the application of substantial pressure to effectivelydeliver the additive to the article, wherein said polymer blendcomprises at least one polymer having a first molecular weight and aglass transition temperature T_(g), and at least one substantiallycrystalline compound having a second molecular weight that is less thanthe first molecular weight of the at least one polymer and having amelting point that is greater than the T_(g) of the at least onepolymer.
 75. An activatable yarn comprising a plurality of fibrousmaterial, said fibrous material comprising a synthetic polymer having afirst molecular weight and a functionalized additive for promotingadhesion of the synthetic polymer to another material and having asecond molecular weight that is less than the first molecular weight ofthe synthetic polymer.
 76. The activatable yarn of claim 75, whereinsaid synthetic polymer comprising a polymer selected from the groupconsisting of polyolefins, polyesters, polyamides, and combinationsthereof.
 77. The activatable yarn of claim 76, wherein saidfunctionalized additive comprises a maleic anhydride modifiedpolyolefin.
 78. The activatable yarn of claim 76, wherein saidfunctionalized additive comprises an amine functionalized additive. 79.The activatable yarn of claim 46, wherein said fibrous materialcomprises at least one polymer having a first molecular weight and aglass transition temperature T_(g), and a substantially crystallinecompound having a second molecular weight that is less than the firstmolecular weight of the at least one polymer and having a melting pointthat is greater than the T_(g) of the at least one polymer.